Mist generator

ABSTRACT

A device for generating a spray of mist or fine droplets includes a spinning rotor within a mist chamber. The rotor has inner walls which taper conically outwardly from the open bottom of the rotor to a hole near the top of the rotor. Liquid is pumped by a finger actuated pump from a cartridge module into a bowl surrounding the bottom end of the rotor. A spray is created as the liquid is formed into droplets as it passes through the hole in the rotor under centrifugal force. A directional light source is used for aiming the spray.

BACKGROUND OF THE INVENTION

The field of the present invention is devices for creating and applyingmists, vapors, or sprays from a liquid, in medical, industrial, andhousehold applications.

The eye is perhaps the most sensitive organ of the body. By contrast toother organs, the slightest touch of the cornea may be irritating andpainful. Similarly, the membrane which covers the remainder of the eye,the conjunctiva, is so thin and delicate that it is normally invisibleunless it becomes irritated. Both the cornea and conjunctiva arenormally kept moist by the constant washing action of tears andblinking.

Because of its sensitivity, many common conditions may irritate the eye.Dry or polluted air, wind, bright light, swimming, dust or chemicalfumes all produce eye irritation. Similarly, contact lenses arefrequently irritating, especially if worn continuously throughout theday.

Surprisingly, few easy to use and effective methods to relax and comfortirritated eyes have been developed. To rid the eye of foreign objects,for example, a saline-filled "eye cup" or eye wash bottle is used. Sinceboth are messy and inconvenient, it is not practical to use either forroutine eye comfort. Another method of relieving seriously dry eyescaused by certain eye diseases employs a small specifically formulatedprescription rod-shaped solid strip (Lacrisert™) which is inserted underthe lower eyelid. Over several hours, the strip dissolves into the tearsand produces a soothing liquid film. Since this product is availableonly by prescription, it is used only in limited and serious eyeconditions.

For the vast majority of people, the only method of applying liquid tothe eye is perhaps the first method ever invented--the eye drop. Many ifnot most substances intended for application to the eye, both over thecounter (OTC) and prescription, are packaged in a container which has abuilt in "eye dropper". Unfortunately, dropping drops into the eye isawkward, inconvenient, uncomfortable and potentially dangerous. For anyparent who has tried to apply drops of liquid into the eye of a smallchild, the prospect of repeating this frequently traumatic action is notappealing. Similarly, applying drops into one's own eye, especially ifone's manual dexterity is not optimum, can be difficult and unpleasantand potentially dangerous to the eye. For many older people who need tofrequently apply eye moistening liquids or eye medications because ofchronic eye disease, eye drops can be very difficult to manage becauseof arthritis, injury or poor hand-eye coordination.

In order to effectively administer a drop to any eye using an eyedropper, the user must position the pointed dropper tip close to thedelicate and sensitive cornea. A slightly unsteady hand or suddenmovement may cause the tip to hit the eye and cause pain, damage andpotentially vision-threatening damage. The awareness of this possibilitymay be keenly appreciated by observing an average user attempt toself-administer eye drops. For this reason, it is dangerous to use eyedrops when the user is in motion or may be bumped in a crowded area. Theuse of a dropper bottle on an airplane, for example, may subject theuser to significant risk given the possibility of an unexpected joltfrom air turbulence or a bump from a fellow passenger.

In ocular drug therapy, it is important that the patient deliver thecorrect amount of drug to the eye. Because of the difficulty of usingand properly aiming eye drops, however, some medication usually dripsdown the face, thus missing its intended therapeutic target. In case ofvision-saving anti-glaucoma drugs or antibiotics, under orover-administration of the drug may have serious repercussions.

Due to the potentially vision-threatening nature of many ocularconditions which require prescription medications, strict patientcompliance with the physician's recommended dosing schedule is veryimportant. Unfortunately, ocular drugs administered by eye drops areunpleasant and difficult to use for many people which results inrelatively poor compliance with the physician's instructions andpotentially serious consequences.

For many eye conditions and diseases, incidence increases with advancingage. As age increases, however, the manual dexterity and eye-handcoordination required for self-administration of eye drops may begreatly reduced. It is difficult enough for a young, healthy person totilt the head back, hold an eye lid open with one hand while trying toaim and drop liquid into the eye with the other hand. For many olderpeople, it is essentially impossible. The fact that many ocular drugsmust be administered as often as four times per day further compoundsthe potential problem. This unfortunate set of common circumstances setsinto motion a potentially vicious cycle which frequently leads toinadequate use of vision-saving eye medications with potentiallycatastrophic results. Accordingly, an improved way of delivering eyemedication would be of great benefit.

The eye is also very susceptible to accidental injury. The inadvertentintroduction of chemicals or foreign bodies into the eye constitutes apotential medical emergency. Rapid intervention by flushing the eye withan inert liquid can potentially prevent irreversible loss of vision.Unfortunately, access to eye wash bottles or fountains in schools,laboratories, industrial settings, at home or during recreationalactivities is sometimes limited. A portable and easy to use eye washdevice would be very useful to help reduce eye injury from foreignchemicals or objects.

Accordingly, there remains a need for a device for safely, accuratelyand conveniently administering drugs or other substances to the eye.

Consumers are increasingly recognizing that cosmetics and personal skincare products have the ability to provide more than just a superficialchange in skin appearance. Cosmetics may also provide protection againstthe potentially damaging ultraviolet rays of the sun and can protectagainst the irritating and potentially skin-threatening environmentalconditions which lead to irritation and premature signs of aging. Forthis reason, consumers recognize that to obtain optimum benefit,skin-protective cosmetics must be applied more often then only duringthe morning and evening rituals common to many customers.

It is, however, awkward and inconvenient for many people to carrymultiple jars and bottles during the day and equally troublesome to opencontainers which may spill and apply cosmetics or fragrances in manysocial or business environments.

Many women and men would like to use skin care products throughout theday but do not because of the inconvenience of conventional applicationmethods. Most skin care products require the customer to use theirfingers or hands to apply and evenly spread the product on the skin.Touching the skin with the fingers, especially for acne-prone people,increases the chances of skin irritation and blemishes. Rubbing productsinto the skin can also leave greasy or oil residues which may remain onthe hands and can be transferred to papers, equipment or other peopleand forces customers to go to the restroom to wash their hands. Thisinconvenience results in many people limiting their use of skin careproducts to the home.

Similarly, the approximately one in ten Americans who wear contactlenses are acutely aware of chemical residues on their hands which maycontaminate the lenses when they are removed and cleaned during the day.This concern is especially applicable to skin "treatment" products ingeneral and sun screen products in particular since many adhere to theskin for extended periods of time even after exposure to water. For thisreason, many contact lens wearers do not use sun screen or skin careproducts during the day unless they have ready access to soap and water.

Another group of people may find it cumbersome or unwieldy to apply skincare products due to their particular environment. Skiers, for example,frequently need facial moisturizers and sunscreens due to the dry, windyand ultraviolet-rich environment of the mountains, but find it awkwardto carry and use multiple bottles or tubes of products. Airlinetravelers have a similar need for frequent facial moisturization due tothe low ambient humidity of airplane cabins, but many find itinconvenient to carry products which may leak or spill in the crowded,depressurized cabin environment.

Many men and women are exposed to low humidity environments whichincrease transepidermal water loss and produce dry, chapped andirritated skin. Air conditioning, forced air heating, airplane travel,high altitudes, desert climates and many other factors result in thefrequent need for facial moisturizers. In many of these environments,however, it is not convenient to carry or use moisturizing products.

During the last several years, consumers have also become acutely awareof the role of ultraviolet radiation in producing sun burn and long-termskin photoaging. Both men and women gravitate towards sun protectionproducts with "light", non-greasy formulations which are invisibleduring wear.

A shortcoming of known aerosol and pump sprays for delivering skin care,fragrances and cosmetic products is the inability to accurately controlthe amount of spray or mist produced. In addition, the pattern and shapeof the spray can be unpredictable, irregular, and vary with the pressureof the propellant or pumping action. Spray velocity and droplet size canalso be inconsistent and difficult to control.

In a conventional pump, the spray can be difficult to aim and the spraypattern is poorly focused. Furthermore, pump sprays deliver only a fixedamount of liquid which may exceed the amount desired by a consumer. Thislack of control of pump sprays frequently results in products stainingclothes, getting into the hair or being sprayed in the eyes or in areasof skin not desired.

Many "high-end", expensive cosmetic formulations use ingredients whichare believed to provide skin-rejuvenating or protection properties.These ingredients include lipids (e.g. ceramide derivatives);glycosaminoglycans (mucopolysaccharides, e.g. hyaluronic acid); "exoticproteins" (e.g. fibronectin, placental proteins); nucleic acids,vitamins (e.g. vitamins C and E), among others.

In many instances, these ingredients are formulated in encapsulated,unit dose vials or capsules to protect the products from exposure to airor the environment which may oxidize or otherwise chemically degrade theingredients. However, these products can be difficult to apply withoutwaste and are relatively expensive.

Many chemicals used in cosmetics can oxidize due to contact with oxygenin the air. Instability of cosmetic ingredients can limit thecircumstances in which desired ingredients can be used or may preventtheir use entirely. For example, ascorbic acid which has been reportedto have beneficial skin-protective effects in humans is unstable when insolution and exposed to air. Many other ingredients derived from"natural" sources such as peptides, vitamins and skin lipids havesimilar instability when formulated in conventional products. There isaccordingly a need for an improved way of applying cosmetics and otherskin care products.

Preservatives in cosmetics and skin care products produce skinirritation in many sensitive skin consumers. Nevertheless, conventionalapplication methods, especially those requiring the user to touch theproduct with the fingers, require the use of preservatives sincemicrobial contamination is difficult to prevent. Accordingly, there is aneed for a device which can hold and dispense preservative-free skincare products while keeping products free of microbial contamination.

Lubricants, paints, solvents, etc. are frequently applied to manyproducts found in the home. Frequent sites of lubricant applicationinclude: door hinges, door locks, nuts and bolts and screws, fans,motors, drawers, windows and many mechanical devices. A common featureof all of these uses is the small size of the lubricated area and itsfrequent location adjacent to rugs, curtains, walls or other objectswhich would be stained or otherwise harmed by the inadvertent contactwith lubricants.

Conventional aerosol sprays used to dispense many lubricants arenotorious for their tendency to splash, ricochet and drip duringapplication. Moreover, these aerosol sprays can be difficult to aim andcontrol. Some aerosol sprays also use propellants which are damaging tothe environment. Thus, there remains a need for a device for sprayinglubricants, paints and other liquids which avoids these disadvantages ofconventional aerosol sprayers.

SUMMARY OF THE INVENTION

The present invention is directed to a mist generator for creating aspray of mist or vapor from a liquid medium. To this end, a spinningrotor draws a liquid medium into a chamber within the rotor. The liquidmedium is centrifugally moved through one or more mist holes through therotor, forming a spray of fine droplets of liquid medium. Multiple mistholes may be vertically aligned (on the same plane of rotation) on therotor, or they may be vertically offset. The spray consists of dropletswhich are large enough to deliver a measurable quantity of liquid withinseveral seconds, to wet e.g., an eye or skin surface. A visible lightbeam aids in aiming the spray. The liquid medium is contained within amodular sealed package and may be pumped to the rotor. Preferably therotor chamber tapers conically outwardly from the bottom to the top.

Accordingly, it is an object of the invention to provide a mistgenerator for medical, skin care, household and industrial uses.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and features of the present invention will become apparentfrom the following detailed description taken in connection with theaccompanying drawings. It is to be understood, however, that thedrawings are designed for the purpose of illustration only, and they arenot intended as a definition of the limits of the invention.

In the drawings, wherein similar reference characters denotes similarelements throughout the several views:

FIG. 1 is a perspective view of the present mist generator;

FIG. 2 is a perspective view showing use of the present mist generator;

FIG. 3 is a partially exploded perspective view of the mist generator ofFIG. 1;

FIG. 4 is a fully exploded perspective view thereof;

FIG. 5 is a right side elevational view thereof;

FIG. 6 is a front elevation thereof;

FIG. 7 is a partial right side section view of the mist generator ofFIG. 1;

FIG. 8 is a partial rear section view thereof;

FIG. 9 is a right side section view of a nebulizing module;

FIG. 10 is a right side section view of a composite cartridge and pumpmodel;

FIG. 11 is a section view taken along line 12--12 of FIG. 7 depicting anembodiment having a light pipe and an LED arrangement;

FIG. 12 is a section view taken along line 12--12 of FIG. 7 depicting apreferred embodiment of an LED arrangement;

FIG. 13 is a section view taken along line 13--13 of FIG. 7;

FIG. 14A is an exploded right side elevation view of a cartridge andpump module including a cap and seal, and a keying arrangement for anebulizing module;

FIG. 14B is a right side elevation view of a nebulizing module for usewith the cartridge and pump module of FIG. 14A;

FIG. 14C is a bottom view of the nebulizing module of FIG. 14B;

FIG. 15A is a rear elevation view of the cartridge and pump module ofFIG. 14A;

FIG. 15B is a rear elevation view of the nebulizing module of FIG. 14B;

FIG. 16 is a right side elevation view in part section of a compositepump and cartridge module;

FIG. 17 is a rear view thereof in part section;

FIG. 18A is an exploded view of non-composite pump and cartridge modulesdisconnected;

FIG. 18B is a right side elevation view of a nebulizing module for usewith the non-composite pump and cartridge module of FIG. 18A;

FIG. 18C is a side section view of the retainer clip used to hold thenebulizing module of FIG. 18B and the cartridge module of FIG. 18Atogether;

FIG. 19A is a rear side elevation view thereof in part section;

FIG. 19B is a rear elevation view of a nebulizing module for use withthe non-composite pump and cartridge module of FIG. 19A;

FIG. 19C is a front elevation view of the retainer clip used to hold thenebulizing module of FIG. 19B and the cartridge module of FIG. 19Atogether;

FIG. 20 is a right side elevation view fragment of the neck and plug ofa bag for containing a liquid medium;

FIG. 21 is a section view of a pump and cartridge module including aremovable cartridge seal;

FIG. 21A is a section view of a removable cartridge seal;

FIG. 22 is a plane view of a mist rotor and anti-vortex baffle;

FIG. 23 is a right side elevation view fragment thereof;

FIG. 24 is an enlarged side elevation view fragment of a mist rotor andseal;

FIG. 25 is an end view thereof;

FIG. 26 is a section view of an alternate mist rotor embodiment;

FIG. 27 is an end view thereof;

FIG. 28 is an enlarged section view fragment of an alternative mistspray aiming system;

FIG. 29 is a side elevation view of an alternative optical spacer blockin the embodiment of FIG. 28;

FIG. 30 is an exploded view in part section illustrating assembly of thenebulizing, pump and cartridge modules;

FIG. 31 is a rear side view thereof;

FIG. 32 is an exploded fragment view in part section of the motor,rotor, seal and optical spacer block shown in FIG. 30;

FIG. 33 is an enlarged perspective view fragment of the rotor of FIG.30;

FIG. 34 is an enlarged schematic view of mist rotor showing preferredgeometries;

FIG. 35 is a plan view fragment of a mist chamber closed off by a safetyshield;

FIG. 36 is a section view thereof;

FIG. 37 is a front elevation view fragment of an installed cleaning anddisinfection module;

FIG. 38 is a section view fragment of an installed cleaning anddisinfection module including an enzymatic insert;

FIG. 39 is a fragment plan view of the enzymatic insert;

FIG. 40 is a plan view of the enzymatic insert installed in the moduleof FIG. 38;

FIG. 41 is a section view of the enzymatic insert;

FIG. 42 is a front elevation view in part section of the enzymaticinsert installed within a cleaning and disinfection module;

FIG. 43 is a rear elevation view of an alternative embodiment fordispensing two separate liquid mediums separately or mixed together;

FIGS. 44, 45 and 46 are partial section view fragments showing theoperation of the embodiment of FIG. 43; and

FIGS. 47-50 are schematic views of the present check valves.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the appended drawings, as shown in FIGS. 1-3, the presentmist generator 1 is a portable self-contained and compact device forgenerating a beam or spray of mist. As shown in FIG. 2, the mistgenerator 1 may be used to apply a spray 7 of liquid medium to theuser's eye. Referring to FIGS. 3 and 4, the present mist generator 1preferably is of modular construction and includes a nebulizing module 4attachable to a cartridge module 2. The cartridge module contains a pumpmodule 3 which may be permanently attached to and disposable with thecartridge module. Alternatively, the pump module may be separable fromthe cartridge module 2 and reusable. When the cartridge module ispermanently attached to the pump module, the resulting combination istermed a "composite" module (e.g. composite cartridge/pump module 5.)

The modular design provides a high degree of flexibility and potentialcost savings. In situations where the mist generator device is usedrepetitively with a single product (e.g., a fragrance or a sunscreen),only the cartridge module 2 as shown in FIGS. 18A and 19A, needs to bereplaced when it is empty while the pump module 3 can be reused.Similarly, for many skin care products, a single pump module 3 may beused in conjunction with multiple cartridge modules 2 over many months.By contrast, for over the counter or prescription drug dispensationwhere the ultimate in cleanliness is important, the single disposablecomposite pump and cartridge module 5, having the pump module 3permanently attached to the cartridge module 2, as shown in FIGS. 3, 16and 17 is used.

Referring to FIGS. 4, 7, 9 and 30, the nebulizing module 4 includes amist rotor 28 attached to the shaft 27 of a high speed miniatureelectric motor 26. The motor 26 is contained within a motor chamber 41formed within a nebulizing module housing 20. A dual-contact momentaryrocker off-on switch 23 is positioned on top of the separate housing 37which, in turn, is on top of the nebulizing module housing 20. A controland communication circuit 25 is supported within the nebulizing modulehousing 20 over the motor 26 and below the switch 23. Switch contacts 24link the switch 23 to the control and communication circuit 25.

N-size alkaline batteries 49 are contained within a battery compartment21. A retainer clip 55, as shown in FIGS. 3, 5 and 9, connects thenebulizing module with the pump/cartridge module 5. To replace thepump/cartridge module, the user grasps the ribbed slide on both sides ofthe device and pulls back until a detent is reached. At this position,the two modules can be pulled apart. To access the battery compartment,the user must push up slightly on the slide to overcome the batteryspring contacts in order to release the detent and then must furtherslide the retainer outwards to expose the batteries. The retainertherefore acts as a battery access door. The slide mechanism alsocontains a conducting battery jumper plate 56 which electricallyconnects the two batteries together. A speaker or sound transducer 46 issupported within the battery compartment and connected to the controland communication circuit 25. Openings may be provided in the nebulizingmodule housing 20 overlying the sound transducer 46. An alpha numericdisplay 34, preferably a liquid crystal or LED display, is positionedwithin the battery compartment and the nebulizing module housing 20. Adisplay window 35 within the nebulizing module housing 20 facilitatesviewing the display 34.

Referring to FIGS. 9 and 30, the top of the nebulizing module housing 20is preferably provided as a separate housing cover 37. The nebulizingmodule housing 20 has an interior wall 30 separating the motor chamber41 from the battery compartment 21. Horizontal walls 48 separate themotor chamber 41 from an upper mist chamber 29, and form a supportsurface for the optical spacer block which, in turn, supports the motor26. A mist port 33 extends through the nebulizing module housing intothe upper mist chamber 29. A mist port cover 38 is attached to thenebulizing module housing 20 at a hinge joint 39, and is pivotable froma closed position, as shown in FIGS. 4, 7 and 30, wherein the mist portcover 38 has a rubber surface which engages and seals the mist port 33(as shown in FIGS. 4, 7, and 28) to an open position, as shown in FIG.9. A conically tapering plug 42 on the mist port cover 38 engages andseals against the mist port 33 when the cover 38 is closed, to preventany leaking, regardless of orientation, as shown in FIGS. 7 and 30.

The motor shaft 27 is inserted into one end of the mist rotor whichextends through an elastomeric type seal 40 which separates the motorchamber from the mist chamber 50, as shown in FIGS. 7 and 24. The seal40 has thin knife edges which contact the rotating sleeve and provide aseal between the two chambers without producing appreciable frictionaldrag.

Referring to FIGS. 9, 11, 12 and 24, an LED 31 is electrically connectedto the control and communication circuit and is contained within anoptical spacer block 51 upon which rests the motor 26 in the motorchamber 41. The optical spacer block contains an LED port 32 and servesto orient the LED so that its illumination is properly directed to aidin aiming the mist beam.

An LED chamber or tunnel 52 is angled slightly downward from thehorizontal and extends through the optical spacer block 51 and holds theLED and precisely aims it toward the mist-impacting point. Depending onthe use (e.g., ocular or skin/lubricant), the LED may be positioned atdifferent positions with the LED tunnel. For example, for skin/lubricantdesigns, the LED will have a rather broad dispersal pattern to match themist shape. In this instance, the LED would be positioned near the leftside of the tunnel closest to the LED port.

By contrast, for ocular uses, the LED and mist beams are very narrow andthe LED beam must be collimated and aimed by the mist port apertureand/or internal light apertures which allow the light beam to be visiblefrom only limited angles. In this instance, the LED is positioned nearthe right side, i.e., to the back, of the LED tunnel.

Additionally, for precise collimation as may be needed for ocular uses,two apertures/baffles within the LED tunnel may be used. As shown inFIG. 12, 24 and 32, the first aperture 53 serves to shape the lightemitted by the LED and is preferably located directly adjacent to theLED. The second aperture 54 is preferably located at the opposite end ofthe tunnel closest to the LED port to serve to "aim" the LED beam andallow it to be observed only from the correct angle which corresponds tothe mist beam.

For administration of ocular drugs for which the most precise aiming isneeded, an alternative embodiment uses two LEDs, as shown in FIGS. 28and 29. The first LED 150 is located in an optical spacer block 149 atan identical location as in the embodiment of FIG. 9. For maximum aimingaccuracy, a second LED 151 is provided within a downward extension 152of the optical spacer block 149 and is located behind and slightlyoffset from the rotor so that the LED 151 is visible when the user's eyeis located in direct line with the mist port. The LED 151 is offset fromthe rotor spin axis by the same degree as the mist port, since the mistdroplets are emitted tangentially from the outer edge of the rotor. Thisoffset (for a rotor spinning clockwise when viewed from above) is shownin FIGS. 4, 6 and 31. Upon actuating the on-off button, both LEDs areilluminated and the device is properly aimed only when both LEDs aresimultaneously visible. In effect, the LED 151 behind the rotor definesthe correct linear axis of the mist beam while the second LED 150located above the mist port defines the correct distance by its beam's"intersection" with the first beam. The intersection of the two beamsdefines the correct distance and position of the device in spacerelative to the user's eye.

In an alternate design, a light pipe 47 shown in phantom in FIG. 11,formed of transparent molded plastic or fiber optics extends from theLED 31 to the LED port 32 and is used to guide the LED beam.

As best shown in FIGS. 7 and 8, the pump module 3 has a pump modulehousing 60. A nebulizing bowl 65 is formed at the front top section ofthe pump module housing 60. An anti-vortex baffle 66 (FIGS. 7, 22 and23) extends partway into the nebulizing bowl 65 and prevents the rapidlyspinning mist rotor 28 from causing the liquid to form a vortex whichwould reduce pumping efficiency and mist production. A bowl supply port73 leads from the nebulizing bowl 65 into the pump module housing. Abracket 57 supports the pump module within the cartridge module (FIG.30).

Referring to FIGS. 7 and 30, with the pump module 3 assembled to thenebulizing module 4, the upper mist chamber 29 and the nebulizing bowl65 form a substantially enclosed mist chamber 50. Alternatively, themist chamber 50 can be formed within an integral component.

As shown in FIGS. 7 and 8, within the pump module housing, an uppercheck valve 70 and a lower check valve 69 are provided above and below adiaphragm 72. The positions of the check valves in these figurescorrespond to the positions attained when the pump diaphragm is beingdepressed and liquid is flowing from the cartridge module into the pumpmodule and from the pump module into the nebulizing bowl. A fingeractuated pump button 67 slidably positioned within the pump modulehousing 60 overlies the diaphragm 72. An input nozzle 75 extends fromthe lower check valve downwardly into a bag neck 85 on a flexibleplastic bag 84 in the cartridge module containing a liquid medium. Theupper check valve 70 output connects with the bowl supply port 73 andprevents any reverse flow from the bowl 65 into the pump or cartridge.Both check valves allow flow only from the plastic bag 84 to the bowlsupply port 73. The one-way liquid flow out of the pump and cartridgeallows their liquid contents to remain free of potential contamination.Alternatively, the cartridge module housing itself may hold the liquidand no bag is used.

Referring to FIGS. 14A-16, one or more keys 92 are optionally providedon the cartridge module housing to allow it to be assembled only to anebulizing module having corresponding key slots 93. The keys and slotscan be used to automatically select only appropriate cartridges foroperation with a particular nebulizing module. For example, a nebulizingmodule designed to dispense eye comfort liquids would mechanically fitonto and accept only eye comfort cartridges and would not accept oculardrug or other cartridge types. Switches in the slots 93 are preferablyelectrically connected to the control and communication circuit toenable it to sense the insertion of a particular type of cartridge(e.g., anti-glaucoma drug) which can then instruct the user via thealpha numeric display how to self-administer the drug (e.g. "One sprayper eye twice per day"). The key and key slot system, in conjunctionwith the control and communication circuit, can also be used to reset analarm or to sense when a cleaning cartridge has been used according tothe appropriate schedule. Through binary coding, use of only a few keyscan provide indications for many different cartridges. For example, withthree keys, as shown in FIGS. 14A and 14C, up to 8 different cartridgescan be identified.

Turning to FIG. 34, preferably, the mist rotor 28 has a stem 120 flaringoutwardly into straight cylindrical outer walls 122. An inner rotorchamber 121 has walls which taper conically outwardly from the bottom ofthe rotor to the top of the rotor. At the top of the chamber 121 is oneor more mist holes 128 extending through the wall 122. The preferreddiameter at the top of the chamber 121 is approximately from 3 to 10 mm.The distance D3 from the bottom of the rotor 28 to the mist hole 128 ispreferably 5 to 20 mm. A scoop 125 having a knife edge is provided atthe bottom of the rotor 28 in order to efficiently spin liquid into therotor interior and preferably forms an angle C to the horizontal equalto angle B minus 10-20 degrees. The distance D1 separating the scoop 125from the bottom edges 124 of the rotor 28 is preferably 2 to 4 mm. Ofcourse, in each instance, other dimensions are possible.

Referring still to FIG. 34, the greater the angle A, the greater will bethe volume pumped by the rotor 28 per unit time. In addition, the volumepumped by the rotor will increase with rotor speed, or with increasednumber or size of mist holes 128. The angle B at the bottom of the rotor28, preferably ranges from about 35°-60°, and most preferably about 45°.Angle B acts to create a fluid vortex in the rotor chamber 121 near theopening 126 which causes liquid to efficiently move via centrifugalforces from the opening 126 into the rotor chamber 121. Within thechamber 121, the fluid medium seeks its own level under centrifugalforces.

The preferred range of angle A is 0.5 to 1.5 degrees. A small angle ispreferred for use with low viscosity spray mediums. A 0 degree angle forangle A, i.e. straight walls, also works but is less efficient as apump. Larger angles, e.g., 1.5 to 10 degrees or more, for angle A, havea higher pump rate, and may be desired for more viscous mediums. Anegative angle A, i.e. a conical chamber wider at the bottom than at thetop, could also work if a liquid lifting mechanism is provided, e.g. anArchimedes screw.

The angled rotor bottom, defined by angle C, helps to pickup small dropsremaining in the nebulizing bowl 65 when the medium or the liquid levelis low. With angle B at 0 degrees, the rotor also works but is lessefficient as a pump and in picking-up drops.

The larger the angle C, the better small drops are picked-up by therotor 28. The angle C should be as close to angle B as possible withoutmaking the knife edge and bottom of the rotor too thin and fragile. Asangle C approaches 0 degrees, the rotor bottom becomes flatter and tendsto spray liquid away from the opening 126, thus reducing the efficiencyof small drop pickup. With angle C at 0 degrees, the rotor operates, butthe ability to pick-up small drops is greatly reduced.

The scoop 125, as shown in FIGS. 25, 27, 33 and 34, although notessential, acts to break-up the surface of the liquid (due to surfacetension) and agitates the liquid sufficiently that some liquid is forcedinto the chamber 121 as the rotor starts to spin. The scoop also greatlyincreases the start-up reliability of the pumping process.

For certain liquids, it is desirable to further modify and break up themist droplets produced by liquid exiting a mist hole 128 in order toproduce an acceptably fine mist. To accomplish this, an alternativeembodiment shown in FIGS. 26 and 27 adds a mist rotor barrier 45 aroundthe hole 128 which flares downwardly below the hole 128. After liquiddroplets exit the hole 128, they are further broken up as they travelalong the lower surface of the mist rotor barrier 45 and impact on therough outer edge of the barrier.

In use, a cartridge module 2 preferably includes a flexible plastic bag84 containing a liquid medium. The bag is sealed with a removable plug86, as shown in FIGS. 18A and 20. The flexible bag 84 eliminates theneed for air intake, as atmospheric pressure induces collapse andemptying of the bag when the pump is activated. By preventing air fromentering the plastic bag, the liquid medium can remain sterile, for drugand preservative free products. Accordingly, sprayed on products whichare subject to oxidation are ideally delivered by the mist generator 1,since no externally derived oxygen or other atmospheric contaminants canenter the bag 84 during use and storage.

As shown in FIGS. 16-19A, two types of liquid-containing modules whichattach to the nebulizing module are provided: (1) a composite modulewhich contains both pump and cartridge components which are permanentlyfastened together during manufacture, and (2) non-composite pump andcartridge modules which are designed to allow the consumer to reuse thepump module with replacement cartridge modules. When the liquid in thecomposite module is used up, the entire composite module is intended tobe discarded, preferably by recycling. By contrast, when the liquid inthe non-composite, detachable pump and cartridge modules is used up, thepump module may be reused by attaching it to a new cartridge module.Alternatively, a partially used cartridge module may be separated from aconnected pump module and re-sealed for storage by inserting plug 86into the neck 85 of bag 84 in the cartridge module. Both composite andnon-composite modules are provided with a removable cartridge seal 98over the nebulizing bowl 65 as shown in FIGS. 14A, 15A, 21, and 21A.

As shown in FIGS. 7 and 8, the lower and upper check valves 69 and 70,respectively, and the diaphragm 72 form a pump 71. The pump 71accurately delivers a defined amount of liquid from the cartridge andtransfers it into the nebulizing bowl 65. Specifically, as the userdepresses the pump button 67, the diaphragm 72 is compressed and expelsa dose of liquid through the upper check valve 70 into the nebulizingbowl 65, through the bowl supply port 73. The lower check valve 69 andupper check valve 70 produce a uni-directional liquid flow from thecartridge module to the nebulizing bowl 65, without any backflow.

The volume of liquid delivered to the nebulizing bowl 65 by the pump 71will vary. In ocular versions, each pump actuation will provide asufficient amount of comfort liquid or drug to saturate the eye withoutoverflowing--about one drop. With skin care products, by contrast, anincreased amount of liquid will be delivered to facilitate mist deliveryto a larger area of the skin. For products that require a specificvolume of liquid to be delivered for each use (e.g., ocular or skindrugs), the volume of liquid delivered by the pump will beadvantageously set at one dose of the substance.

The switch 23 on top of the nebulizing module is ergonomically placed atthe natural resting position of the user's index finger, for both rightand left handed users. As the switch 23 is rocked to the rear, the LED31 illuminates generating a light beam which projects forward, foraiming purposes. For ocular versions, the light beam is visible onlywhen the mist generator 1 is properly aimed to administer mist to theviewing eye. In skin care versions, or versions used to dispenselubricants, paints, solvents, surface protecting liquids, etc., a higherintensity beam is used to illuminate the area of skin on which the mistwill be deposited. The LED may be any available color, especially red,yellow, amber or green. As the switch 23 is rocked forward, the motor 26is energized and spins the rotor 28.

The rotor 28 is designed to function as a pump to draw liquid into therotor chamber 121 and induce flow upwardly towards the mist hole 128.After the diaphragm pump is actuated, the bottom of the rotor 28 isimmersed in the liquid medium contained within the nebulizing bowl 65.As the liquid enters into the bottom of the spinning rotor 28, theliquid accelerates and eventually spins along with the rotor 28. Theconical taper of the cone chamber 121 continuously extends to a largerdiameter, which, coupled with centrifugal force experienced by theliquid spinning with the rotor, causes the liquid to travel "downhill"on the inclined surface of the rotor and therefore upward towards thetop of the rotor chamber 121. As the liquid is forced through the misthole, mist droplets, of a defined size are formed, and are flungradially outwardly due to the centrifugal force of the spinning rotor. Afraction of the mist droplets exit through the mist port 33 as a focuseduniform spray or beam of mist, suitable for a variety of medical, skincare, industrial and household uses. The mist beam travels directly fromthe rotor to the targeted surface.

The size and shape of the mist port can be varied to adjust the spraypattern. The mist port can be made adjustable with sliding closures ordiaphragm-like radially adjustable apertures. Multiple vertically spacedholes in the rotor combined with an elongated rectangular mist port maybe used to provide a long narrow rectangular mist beam, for household,industrial or skin applications.

A shadow mask may be provided immediately behind the mist port, in themist chamber, to shape the beam of mist and/or to stop any dripping onthe outside of the mist port.

Mist droplets that impact the interior of the rotor mist chamber 50 flowdownwardly to the bottom of the rotor mist chamber back into thenebulizing bowl 65 and are recirculated by the pumping action of therotor 28. The number and size of the mist holes 128 can be varied,depending on the viscosity of the liquid used and the desired mistqualities.

For ocular comfort mist and ocular drugs, the mist will be very fine anda low volume. In contrast, an ocular first-aid product will produce amuch larger quantity of coarser mist, so that the eye can be rapidlyflushed of foreign bodies or chemical contaminants. Cosmetics and skinfirst-aid will also advantageously have a higher rate of mist in orderto effectively cover the skin in several seconds. For delivery offragrance products, a very small quantity of fine mist, similar to anocular mist, is desirable.

The mist generator 1 can dispense different types of products byexchanging cartridge modules 2. A consumer may, for example, remove askin moisturizing cartridge, re-seal it with the cartridge seal 98, andreplace it with a sunscreen cartridge. Since virtually all residualliquid from the first cartridge is automatically removed from thenebulizing bowl during use, mixing of products is negligible.

For many skin care products, the mist generator 1 will use a rotor 28selected to produce a mist similar in quality to a fog. Within severalseconds, the mist will form a thin liquid layer. In such embodiment, theconsumer will experience little or no sensation of mist impact on theskin which will be particularly advantageous for application of productslike antiseptics, burn medications or local anesthetics to abraded,burned or otherwise delicate or sensitive skin. Similarly, many otherproducts for skin care may be advantageously applied which includesunscreens or other skin-protective liquids, moisturizers, cosmetics,fragrances, insect repellents, anti-acne medications, antimicrobialsubstances, products for therapy of skin diseases, lipsome-basedproducts or any other product useful for skin care which can bedispensed as a mist. For industrial or hobby use, lubricants, thinners,paints, solvents, surface-protective products, etc. can be applied,without the use of volatile organic compounds or propellants whileavoiding the risk of spills, dripping, splashing, running or impactingon non-intended areas. Of course, for personal, industrial or hobby use,virtually any liquid can be applied by the mist generator. Of course,the outside shape and size of the mist generator may vary with itsintended applications. For example, for household and individual uses,the cartridge module may be large and/or handle-shaped.

For delivery of a medium to the eye, the mist generator has severaladvantages over droppers. The LED allows the user to determine when themist port 33 is properly aligned. Thus, the dose can be reliable appliedto the eye in a uniform distribution, without any appreciable impact.Risk of injury to the eye is avoided as no pointed eyedropper tip isused. The mist generator 1 is accordingly also advantageous for applyingeye drop liquids or medications to children and for use by others withlimited eye-hand coordination.

The control and communication circuit 25 may include a processor, memoryand clock, depending upon the application. Optionally, the control andcommunication circuit 25 can be programmed to communicate to the uservia the alpha numeric display 34 or the sound transducer 46, that themist generator 1 has been used sufficiently to require cleaning with thecleaning module 95. For dispensation of certain products, for exampleocular drugs, it may be particularly advantageous to program the controland communication circuit to operate the motor for a minimum time afterthe motor is actuated to assure that all of the drug in the nebulizingbowl is dispensed. Other functions that the control and communicationcircuit may optionally provide through the alpha numeric display 34and/or sound transducer 46 are: remaining battery power; when toadminister a product (or an alarm); dosing instructions; recordingnumber and timing of uses for a daily log, or displaying other messages.Additionally, the control and communication circuit may allow the userto vary the speed of the motor.

The control and communication circuit 25 can also be programmed toprevent actuation of the mist generator 1, unless the cleaning cartridge95 is used according to a particular schedule. Optionally, the cartridgekeying system can provide an indication to the control and communicationcircuit 25 that the cleaning and disinfecting cartridge 95 has beeninserted, with the control and communication circuit 25 programmed tooperate the motor for a preset period of time to assure an adequatecleaning.

Thus, the control and communication circuit 25 can provide suggestionsand reminders to the user, and can also disable the mist generator 1unless and until a user follows specific instructions.

A daily use log, as recorded in the memory of the control andcommunication circuit 25, can be used by a health care provider tomonitor the patient's compliance with prescribing instructions.Compliance monitoring can greatly aid in the conduct of clinical trialsof experimental drugs and can help health care providers optimize drugadministration. For this use, the control and communication circuit mayadditionally have an electronic interface to allow the connection of anexternal device which can read the data stored in the memory of thecontrol and communication circuit.

For visually impaired users, voice synthesis may be included in thecontrol and communication circuit 25 to provide verbal instructions, viathe sound transducer 46. The sound transducer 46 can also act as analarm, e.g., to remind users when to reapply a sunscreen at the beach.The control and communication circuit 25 may also be programmed toprovide music or sound effects, for use with children or young adults.

In an alternative embodiment without a control and communicationcircuit, a mechanical or electrical timer is used to automatically runthe motor for a pre-set time (e.g. 4-5 seconds), to insure all liquid inthe nebulizing bowl is emptied. This reduces the likelihood ofmicroorganisms growing in residual liquid left by the user due toinsufficiently long running of the motor.

As shown in FIGS. 43-46, a dual medium cartridge 100 has a selectionswitch 105 on its back surface. First and second bags 103 and 104 areprovided within the dual chamber cartridge 100. The first bag 103 has adelivery hose 109 passing through a hose collar 111 leading to aY-branch 112. A slide pincher 107 attached to the switch 105 pinches offthe delivery hose 109. On the opposite side of the cartridge 100 is asymmetrical arrangement with bag 104 having a delivery hose 110 passingthrough a collar and leading to the Y-branch. As shown in FIG. 44, withthe selection switch 105 in position A, the pincher 107 pinches off thedelivery hose 109, while delivery hose 110 remains open. As shown inFIG. 45, with the selection switch 105 in position B, the slide pincher107 pinches off delivery hose 110, while delivery hose 109 remains open.As shown in FIG. 46, the selection switch 105 in position C is centeredand both delivery hoses 109 and 110 are open so that contents of bothbags 103 and 104 can be pumped out and mixed together.

The embodiment of FIGS. 43-46 may be especially useful when two productsare commonly used in conjunction with one another. For example, a skierin a cold, dry environment may desire to apply a moisturizer to preventskin chapping, followed by a sunscreen. Similarly, a hiker or sportsenthusiast may apply a biting insect repellent followed by an anti-itchlocal anesthetic for areas already bitten or may apply a sunscreen andan anti-pain local anesthetic to already sunburned skin using theembodiments of FIGS. 43-46.

The embodiment of FIGS. 43-46 may also be particularly useful toadminister a mixture of two substances which together are chemicallyunstable but when apart are relatively stable. For example, many drugsintended for ophthalmic administration are very soluble and relativelychemical stable at acidic pH (e.g., PH=2 to 6), but are relativelyinsoluble and unstable at the neutral pH of tears (pH=7.4). The eye is,however, very sensitive to irritation by acidic solutions andsubstantially acidic solutions cannot be used. One study, for example,found that 99% of people tested reported that ocular solutions with a pHof 5.8 were irritating (Deardorff, D. L., 1980, "OphthalmicPreparations." Remington's Pharmaceutical Sciences, Eds. A Osol, et al.Easton, Pa.: Mack Publishing Company, 1504-1506). For this reason, manyophthalmic drugs are formulated at approximately neutral pH which doesnot produce irritation but which reduces the stability and shelf-life ofthe drugs.

The dual medium cartridge can be used to substantially solve thisproblem. In one bag, an ophthalmic drug is contained at an optimumacidic pH to increase stability and solubility. The other bag contains aneutral pH buffer. For this use, the design shown in FIGS. 43-46 ismodified so that the selector switch is fixed to allow both bags to besimultaneously emptied by the pump at a mixing ratio which can bedetermined and fixed during manufacture. By actuating the pump, liquidfrom both bags is mixed in the pump and nebulizing bowl which results inthe buffer changing the pH of the combined solution to a non-irritatingneutral pH. Upon activating the motor, the spinning action of the rotorfurther ensures complete mixing of the solution for optimum comfort andsafety.

A similar technique may be used to stabilize or otherwise modifycompounds, which are stable under "non-physiological" chemicalconditions, but which may be converted to a form that is physiologicallyacceptable by the addition of a second chemical solution contained inthe second bag.

Similarly, this technique may be used to dispense any two liquids forwhich it is advantageous to store two components separately and combinethem at the time of dispensation.

It should be noted that the second bag which contains the "modifyingsolution" may have a different size from the first bag (e.g., it may bemuch smaller in the case of a buffer.) This embodiment is also useful inindustrial and hobby applications. For example, the mist generator 1 canbe used as an air brush with different color paints provided in bags 103and 104.

A composite cleaning and disinfectant module 95, as shown in FIGS. 35-42is attachable to the nebulizing module 4, in the same manner as acartridge module 2. A disinfecting liquid medium contained within thecleaning module 95 is pumped into the mist chamber 50, as is any othermedium. A particularly preferred disinfecting liquid is an aqueoussolution of hydrogen peroxide (e.g., 3% hydrogen peroxide) since it isan effective disinfectant and decomposes into water and oxygen and thusleaves no residue. When hydrogen peroxide is used as a disinfectant, itmay be desirable to have a catalyst incorporated into the nebulizingbowl 65 to insure that all hydrogen peroxide is fully decomposed towater and oxygen after the cleaning process is completed. To accomplishthis, a hydrogen-peroxide decomposing catalyst or enzymatic insert 140is inserted into the nebulizing bowl which is immersed in the hydrogenperoxide disinfecting solution, as described in U.S. Pat. No. 3,912,451incorporated herein by reference. A particularly preferred catalyst isplatinum black which is coated in a thin layer on a solid plasticsupport. After the cleaning process is completed, the disinfectingsolution is left to remain in the nebulizing bowl for a period of timesufficient to insure that the hydrogen peroxide is fully decomposed intowater and oxygen. The spinning rotor sprays the disinfecting medium toclean the interior of the rotor 28 and the mist chamber 50. The safetyshield 96 built into the cleaning and disinfecting cartridge 95 preventsthe escape of any mist or liquid during cleaning, even if the mist portis inadvertently left open, to prevent the possibility of the userinadvertently spraying the disinfecting medium. After cleaning, thecartridge 95 is removed from the nebulizing module and the remainingcleaning liquid poured out.

The construction of the check valves is shown in FIGS. 47-51. As shownin FIGS. 47 and 48, a molded silicone rubber valve element 160 has agenerally curved rectangular base 161 and a centered conical stopper162. The base, by its shape, provides its own spring action. FIG. 49shows the valve element 160 as installed in a valve housing 163, in theclosed position. Under pressure, the valve element bows upwardlyunsealing the stopper from the supply line 164. Liquid can then flowpast the valve element into the delivery line 165. When pressure isremoved, the spring force in the deformed base returns the stopper intothe supply line 164. If pressure is created in the delivery line 165,the stopper is pushed with even additional force into the supply line164, to prevent back flow. This design is exceptionally compact andproduces accurate and consistent fluid delivery, without backflow. Metalcomponents, e.g., springs, which can result in corrosion andcontamination due to ion transfer and similar reactions, are avoided.Various elastomeric plastics may be used for the valve depending ontheir compatibility with the pumped medium.

Thus, a novel mist generator is disclosed. While embodiments andapplications of this invention have been shown and described, it wouldbe apparent to those skilled in the art that many more modifications arepossible without departing from the inventive concepts herein. Theinvention, therefore, is not to be restricted except in the spirit ofthe appended claims.

We claim:
 1. A mist generator comprising:a housing; a mist rotor withinthe housing and having at least one mist hole, rotatably supportedsubstantially within a mist chamber; means for rotating the mist rotor,supported by the housing; a bowl in the mist chamber for supplying afluid medium to the mist rotor; and a bowl supply port in the bowl forsupplying a mist medium.
 2. The mist generator of claim 1 wherein themist rotor has a conically tapering inner surface with the at least onemist hole extending through the rotor to the inner surface.
 3. The mistgenerator of claim 2 further comprising a mist port extending throughthe housing into the mist chamber.
 4. The mist generator of claim 3further comprising means for aiming the mist port.
 5. The mist generatorof claim 4 wherein the means for aiming comprises a light beam.
 6. Themist generator of claim 1 further comprising an anti-vortex means in themist chamber.
 7. The mist generator of claim 6 wherein the anti-vortexmeans comprises a vertical surface adjacent the mist rotor.
 8. The mistgenerator of claim 1 further comprising shaping means attached to thehousing for shaping a mist spray.
 9. The mist generator of claim 1further comprising a pump connected to the bowl supply port.
 10. Themist generator of claim 9 further comprising a cartridge moduleattachable to the housing for holding mist medium.
 11. A device forgenerating a spray of fine surface-wetting droplets of a liquidcomprising:a nebulizing module including:a nebulizing module housing; amotor within the nebulizing module housing, the motor including a shaft;a rotor mounted on the shaft and supported in a mist chamber; a mistport extending through the nebulizing module housing into the mistchamber; a directional light source within the nebulizing module housingfor targeting the spray; a switch means for actuating the motor anddirectional light source; attachment means on the nebulizing modulehousing for attaching it to another module; a pump and cartridgecomposite module attached to the nebulizing module by said attachmentmeans and including:a composite module housing; a cartridge for holdinga liquid within the composite module housing; anda finger actuated pumpwithin the composite module housing for pumping the liquid from thecartridge to the mist chamber in the nebulizing module.
 12. The deviceof claim 11 further comprising anti-back flow means linked to the pumpto prevent back flow into the composite module housing.
 13. The deviceof claim 11 further comprising a slot on one of the nebulizing moduleand composite module for accepting a key.
 14. The device of claim 13further comprising a key detection switch adjacent the slot fordetecting the presence of a key in the slot.
 15. The device of claim 11further comprising a control and communication circuit within thenebulizing module and linked to the motor, light source, and switchmeans.
 16. The device of claim 15 further comprising one of analphanumeric display and a sound transducer linked to the control andcommunication circuit.
 17. A device for generating a spray of finesurface-wetting droplets of a liquid comprising:a nebulizing moduleincluding:a nebulizing module housing; a motor, within the nebulizingmodule housing, the motor having a shaft; a rotor mounted on the shaftand supported in a mist chamber; a mist port extending through thenebulizing module housing into the mist chamber; a switch on the devicefor actuating the motor; a pump module attached to the nebulizing modulehousing; a cartridge module attached to the pump module, for containingthe liquid; and a pump in the pump module for pumping the liquid fromthe cartridge module into the mist chamber of the nebulizing module.